CN113281862A - Manufacturing method of optical cable for aerospace - Google Patents
Manufacturing method of optical cable for aerospace Download PDFInfo
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- CN113281862A CN113281862A CN202110485332.3A CN202110485332A CN113281862A CN 113281862 A CN113281862 A CN 113281862A CN 202110485332 A CN202110485332 A CN 202110485332A CN 113281862 A CN113281862 A CN 113281862A
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- 239000013307 optical fiber Substances 0.000 claims abstract description 46
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- 230000003014 reinforcing effect Effects 0.000 claims abstract description 17
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- 229920002748 Basalt fiber Polymers 0.000 claims description 8
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 8
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 claims description 8
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4479—Manufacturing methods of optical cables
- G02B6/4486—Protective covering
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/06—Rod-shaped
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/24—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using threads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
- B29C69/007—Lining or sheathing in combination with forming the article to be lined
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Abstract
The invention relates to a manufacturing method of an optical cable for aerospace, which comprises the following steps: the optical fiber buffer layer is wrapped on the outer side of the optical fiber, the enhancement layer is wrapped on the outer side of the buffer layer, and the outer protection layer is wrapped on the outer side of the enhancement layer, wherein the manufacturing method comprises the following steps: fabricating an optical fiber comprising: the optical fiber comprises a fiber core, a cladding and a coating, wherein 0.03-0.5% of fluorine element is added into the fiber core and the cladding, the coating is ultraviolet-cured acrylic resin, and the irradiation induced loss is lower than 4dB/100m under the irradiation dose of 20 Mrad; forming a buffer layer on the outer side of the optical fiber in an extrusion molding mode; weaving 16 strands of fiber yarns outside the buffer layer to form a reinforcing layer, wherein the fiber paying-off tension is 0.5N-1N; and forming the outer protective layer by weaving the reinforcing layer by using a weaving machine, wherein the elastic modulus of the fiber yarn of the outer protective layer is more than 2.1Gpa, the weaving density is more than 99.9 percent, and the fiber paying-off tension is 1N-1.5N.
Description
Technical Field
The invention relates to a method for manufacturing an optical cable, in particular to a method for manufacturing an optical cable for aerospace.
Background
The invention belongs to the technical field of optical fiber communication, and particularly relates to an optical cable for aerospace, which is used for interconnection communication among spacecraft equipment, high-speed transmission of optical signals such as high-capacity voice, images, videos and the like, can be used in or out of a spacecraft cabin, and can meet the adaptability of aerospace environments such as space irradiation, high-low temperature alternation, low loss, high reliability and the like.
With the increase of space detection activities of human beings, launched spacecrafts increase year by year, the aerospace optical cable is gradually replacing the traditional optical cable with unique advantages to be used in the spacecrafts, the aerospace environment is different from the ground environment, and the aerospace optical cable has the characteristics of high irradiation, wide temperature change, high vacuum and the like, the temperature alternation period is short, the optical cable is subjected to temperature alternation for ten thousand times in the orbit period, the optical cable is greatly examined, the current aerospace optical cables all adopt fluoroplastics as outer sheaths, the fluoroplastics have the characteristic of large molding shrinkage, and the optical cable sheaths can be separated from connectors due to shrinkage, and even transmission loss can be influenced. The aerospace special environment has two main effects on the optical cable: the optical cable loss is increased, large temperature stress is generated due to wide temperature change of an aerospace environment, and the stress acts on the optical fiber to cause optical fiber micro-bending, so that the optical cable loss is increased; and secondly, the optical cable structure is unstable due to long-term alternation, the contraction characteristic of the optical cable is aggravated by the alternating temperature stress, the optical cable structure is layered, and the optical cable can fail in severe cases. The aerospace launching cost is high, spacecraft devices are not easy to replace and have non-maintainability, aerospace products seriously affect the service performance of the spacecraft once the aerospace products fail, and even can cause the failure of the whole aerospace activity, most of the current aerospace optical Cables adopt a heat treatment (Fiber optical Cable Assemblies for Space Flight Applications III: diffraction of commercial Cables for Thermal Effects) mode to release the structural shrinkage of the optical Cables in advance, reduce the risk in the in-orbit use process, and still cannot fundamentally solve the problem.
The first technical scheme in the prior art is as follows: mainly has fluorine tight package structure, around package loose tube structure.
The fluorine tight-packing technical route adopts fluoroplastic as a tight-packing layer of an optical fiber, fiber materials as a reinforcing unit of the optical cable, and an outer sheath is also formed by fluoroplastic in an extrusion mode. The fluorine material linear expansion coefficient is great among this technical route, two orders of magnitude higher than optic fibre, the temperature stress that produces under high low temperature is great, lead to optic fibre transmission loss big, in addition, the oversheath adopts fluoroplastics, the extrusion mode is high temperature extrusion, macromolecular material is first through high temperature plastify extrusion cooling shaping again, fluoroplastics is a crystalline polymer, have higher shaping shrinkage factor, can have the condition of sheath shrink in the use, can break away from the connector with the sheath when contracting to a certain extent, cause the cable core to expose, thereby influence the reliability of optical cable.
The second technical solution in the prior art is: the lapping loose tube technical route is that a thin film lapping optical fiber made of fluorine materials is used for forming a protective layer of the optical fiber, a reinforcing unit is made of fiber materials, and an outer sheath is made of fluoroplastic through extrusion molding. This technical route buffer material mainly is fluoroplastics, has certain shrink under high and low temperature, and the loose structure excess length of optic fibre is difficult to control, and the uneven distribution of excess length of optic fibre can lead to the loss crescent under the high and low temperature stress alternation, and the oversheath adopts fluoroplastics equally, also has great shrink problem, can lead to structure size unstability under the long-term use.
Under the aerospace environment, the temperature alternation is fast, the temperature alternation range is wide, the technical scheme uses fluoroplastics, high-temperature extrusion molding is needed in the manufacturing process of the outer sheath, the shrinkage after molding cannot be avoided, the main means at present is to reduce the shrinkage of the aerospace optical cable by adopting a heat treatment mode, but the heat treatment mode cannot fundamentally solve the problem of structural stability of the optical cable under high-temperature and low-temperature alternation, and in addition, the technical scheme adopts larger buffer protection stress, so that the cable forming loss is larger.
Disclosure of Invention
The invention aims to overcome the defects of large loss and low reliability of the conventional optical cable and provide a novel optical cable for aerospace with low loss and high reliability.
In order to achieve the purpose of the invention, the following technical scheme is adopted in the application:
the invention relates to a manufacturing method of an optical cable for space navigation, which comprises the following steps: the optical fiber buffer layer is wrapped on the outer side of the optical fiber, the enhancement layer is wrapped on the outer side of the buffer layer, and the outer protection layer is wrapped on the outer side of the enhancement layer, wherein the manufacturing method comprises the following steps:
(a) manufacturing an optical fiber;
(b) forming a buffer layer on the outer side of the optical fiber in an extrusion molding mode;
(c) weaving a reinforcing layer on the outer side of the buffer layer;
(d) wrapping an outer protective layer outside the enhancement layer in a weaving or wrapping mode;
wherein:
the optical fiber in step (a) comprises: the optical fiber comprises a fiber core, a cladding and a coating, wherein 0.03-0.5% of fluorine element is added into the fiber core and the cladding, the coating is ultraviolet-cured acrylic resin, and the irradiation induced loss is lower than 4dB/100m under the irradiation dose of 20 Mrad;
in the step (b), an extruding machine is adopted, in the foaming and extruding process, the extruding temperature is controlled to be 370-400 ℃, the foaming degree reaches 60-65%, the size of a foam hole is controlled to be below 20 mu m, the extruded optical fiber coated with the buffer layer is cooled by cooling water, the temperature of the cooling water is lower than 80 ℃, and the thickness of the thin wall of the buffer layer (2) is controlled to be 0.2-0.3 mm;
in the step (c), 16 strands of fiber yarns are woven outside the buffer layer to form a reinforcing layer, and the fiber paying-off tension is 0.5N-1N;
in the step (d), forming an outer protective layer outside the reinforcing layer by weaving a fiber yarn, wherein the elastic modulus of the fiber yarn for weaving the outer protective layer is more than 2.1Gpa, the outer protective layer works at the temperature range of-150-300 ℃, the outer protective layer is formed by weaving 24 strands of fiber yarns, the weaving pitch is controlled within 10mm, the weaving density is more than 99.9 percent, and the fiber pay-off tension is 1N-1.5N; or the outer sheath is formed by a film wrapping mode outside the enhancement layer, the outer sheath works at the temperature range of-150-300 ℃, the tensile modulus is greater than 200MPa, the thickness of the film is 50 microns, the wrapping tension of the film is 1N-1.5N in the wrapping process, and the wrapping angle of the film is greater than 60 degrees.
The invention relates to a manufacturing method of an optical cable for space navigation, which comprises the following steps: in the step (b), the buffer layer is a low expansion stable buffer layer, and the buffer layer is any one of expanded fluoride, foaming fluoride, copolyester or aromatic polymer.
The invention relates to a manufacturing method of an optical cable for space navigation, which comprises the following steps: in the step (c), the reinforcing layer is any one of polyimide fiber, modified aramid fiber, special glass fiber, metal-plated fiber, basalt fiber, carbon fiber and stainless steel wire, and is formed by weaving.
In the manufacturing method of the optical cable for aerospace, in the step (d), the fiber of the outer sheath is any one of polyimide fiber, modified aramid fiber, special glass fiber, metal-plated fiber, basalt fiber and carbon fiber, and the outer sheath is formed by adopting a physical weaving mode.
The invention relates to a manufacturing method of an optical cable for space navigation, which comprises the following steps: in the step (d), the film of the outer sheath is any one of a polyimide film, an aromatic polymer film and a polyether-ether-ketone film, and the outer sheath is formed in a wrapping mode.
The buffer layer outside the optical fiber is designed into a low-expansion stable structural layer, the linear expansion coefficient of the buffer layer is similar to that of the optical fiber, the influence of temperature stress on the optical fiber can be reduced to the maximum extent, meanwhile, the direct action of the stress of other outer layer structures of the optical cable and the external environment on the optical fiber can be buffered, the optical fiber is prevented from being slightly bent, the loss is prevented from being increased, and the low loss of the optical cable is realized. The outer sheath is designed by adopting high-stability units, is made of high-strength high-modulus materials, has the characteristic of stable size, adopts a physical forming mode in the process, is different from the traditional aerospace optical cable high-temperature sheath extrusion forming mode, avoids the generation of residual stress in the high-temperature processing process of high polymer materials, and greatly improves the structural reliability of the optical cable.
Drawings
FIG. 1 is a schematic structural view of an aerospace optical cable braided outer sheath according to the present invention.
Fig. 2 is an enlarged schematic view of the optical fiber of fig. 1.
In fig. 1 and 2, reference numeral 1 is an optical fiber; reference numeral 2 is a buffer layer; reference numeral 3 is an enhancement layer; reference numeral 4 is an outer jacket; reference numeral 5 is a coating layer; reference numeral 6 is a core; reference numeral 7 denotes a cladding.
Detailed Description
Example 1
As shown in fig. 1 and 2, the optical cable of the present invention includes: the optical fiber comprises an optical fiber 1, a buffer layer 2, an enhancement layer 3 and an outer protective layer 4, wherein the buffer layer 2 is wrapped outside the optical fiber 1, the enhancement layer 3 is wrapped outside the buffer layer 2, the outer protective layer 4 is wrapped outside the enhancement layer 3,
the manufacturing method comprises the following steps:
(a) manufacturing an optical fiber 1; the optical fiber 1 includes: the optical fiber comprises a fiber core 6, a cladding 7 and a coating layer 5, wherein 0.03-0.5% of fluorine element is added into the fiber core 6 and the cladding 7, the coating layer 5 is ultraviolet light cured acrylic resin, and the irradiation induced loss is lower than 4dB/100m under the irradiation dose of 20 Mrad;
(b) forming a buffer layer 2 on the outer side of the optical fiber 1 by an extrusion molding mode; adopting an extruding machine, controlling the extruding temperature to be 370-400 ℃, the foaming degree to be 60-65% and the cell size to be below 20um in the foaming and extruding process, cooling the extruded optical fiber 1 coated with the buffer layer 2 by using cooling water, wherein the cooling water temperature is lower than 80 ℃, and the thin wall thickness of the buffer layer (2) is controlled to be 0.2-0.3 mm; the buffer layer 2 is a low-expansion stable buffer layer, and the buffer layer 2 is any one of expanded fluoride, foaming fluoride, copolyester or aromatic polymer;
(c) weaving a reinforcing layer on the outer side of the buffer layer; the buffer layer 2 is externally woven with 16 strands of fiber yarns to form a reinforced layer 3, the fiber paying-off tension is 0.5N-1N, the reinforced layer 3 is any one of polyimide fiber, modified aramid fiber, special glass fiber, metal-plated fiber, basalt fiber, carbon fiber and stainless steel wire, and the reinforced layer is formed by weaving.
(d) Wrapping a protective layer outer protective layer outside the enhancement layer in a weaving mode; forming an outer protective layer 4 outside the reinforcing layer 3 by weaving fiber yarns, wherein the elastic modulus of the fiber yarns for weaving the outer protective layer 4 is more than 2.1Gpa, the outer protective layer 4 works at the temperature range of-150-300 ℃, the outer protective layer 4 is formed by weaving 24 strands of fiber yarns, the weaving pitch is controlled within 10mm, the weaving density is more than 99.9 percent, and the fiber pay-off tension is 1N-1.5N; the fiber of the outer sheath 4 is any one of polyimide fiber, modified aramid fiber, special glass fiber, metal-plated fiber, basalt fiber and carbon fiber, and the outer sheath 4 is formed by adopting a physical weaving mode.
The optical cable for aerospace of the invention includes optical fiber 1, low-expansion stable buffer layer 2, reinforcing unit 3 and fiber outer sheath 4. The optical fiber 1 is a specially designed irradiation-resistant optical fiber, and the irradiation resistance of the optical fiber can be realized by improving the purity of the optical fiber or special doping in a mode of pure silicon core, fluorine doping of a cladding and fluorine doping of a core package. The low-expansion stable buffer layer 2 is formed by extruding any one of expanded fluoride, foaming fluoride, copolyester or aromatic polymer, and because the material of the buffer layer is close to the linear expansion coefficient of the optical fiber, the influence of the generated high and low temperature stress on the optical fiber is low, and meanwhile, the extruded buffer layer has low molding shrinkage and stable and reliable structure. The reinforcing unit 3 can be any one of polyimide fiber, modified aramid fiber, special glass fiber, metal-plated fiber, basalt fiber, carbon fiber and stainless steel wire, and can be realized by weaving, and the reinforcing unit is made of a high-strength high-modulus material and provides certain working strength for the optical cable. The fiber outer sheath 4 can be any one of polyimide fiber, modified aramid fiber, special glass fiber, metal-plated fiber, basalt fiber and carbon fiber, and is manufactured by adopting a physical weaving mode, the sheath material is a high-strength high-modulus fiber material and has the characteristics of wear resistance, strength support and stable size, in addition, the outer sheath is formed by adopting physical weaving, so that the release of residual stress in the high-temperature processing process of a high polymer material is fundamentally avoided, the structural reliability of the optical cable is greatly improved, and the problem of shrinkage of the sheath of the traditional aerospace optical cable is solved.
Example 2
Steps (a) to (c) of example 2 are the same as steps (a) to (c) of example 1, and the same points are not described again except for the following step (d).
In the step d, or the outer sheath 4 is formed outside the enhancement layer 3 in a film wrapping mode, the film of the outer sheath 4 is any one of a polyimide film, an aromatic polymer film and a polyether-ether-ketone film, the outer sheath 4 is formed in a wrapping mode, the outer sheath works at the temperature range of-150-300 ℃, the tensile modulus is larger than 200MPa, the thickness of the film is 50 micrometers, the wrapping tension of the film is 1N-1.5N in the wrapping process, and the wrapping angle of the film is larger than 60 degrees.
In the embodiment, the outer sheath 5 can be any one of a polyimide film, an aromatic polymer film and a polyether-ether-ketone film, the process is realized by wrapping the film, the selected film material has the characteristics of wear resistance, strength support and stable size, and in addition, the outer sheath is formed by wrapping to fundamentally avoid the release of residual stress in the high-temperature processing process of a high polymer material, so that the structural reliability of the optical cable is greatly improved, and the problem of shrinkage of the sheath of the traditional aerospace optical cable is solved.
The above-mentioned embodiments are merely illustrative of the preferred embodiments of the present invention, and do not limit the scope of the present invention, and those skilled in the art should make various changes and modifications to the technical solution of the present invention without departing from the spirit of the present invention, which falls within the scope of the present invention defined by the claims.
Claims (5)
1. A method for manufacturing an optical cable for aerospace, the optical cable comprising: optical fiber (1), buffer layer (2), enhancement layer (3) and outer jacket (4), buffer layer (2) parcel is in optical fiber (1) outside, and enhancement layer (3) parcel is in buffer layer (2) outside, and outer jacket (4) parcel is in enhancement layer (3) outside, and its manufacturing method includes the following step:
(a) manufacturing an optical fiber (1);
(b) forming a buffer layer (2) on the outer side of the optical fiber (1) by an extrusion molding mode;
(c) weaving a reinforcing layer on the outer side of the buffer layer;
(d) wrapping an outer protective layer outside the enhancement layer in a weaving or wrapping mode;
the method is characterized in that:
the optical fiber (1) in step (a) comprises: the coating comprises a fiber core (6), a cladding (7) and a coating layer (5), wherein 0.03-0.5% of fluorine element is added into the fiber core (6) and the cladding (7), the coating layer (5) is made of ultraviolet light cured acrylic resin, and the irradiation induced loss is lower than 4dB/100m under the irradiation dose of 20 Mrad;
in the step (b), an extruding machine is adopted, in the foaming and extruding process, the extruding temperature is controlled to be 370-400 ℃, the foaming degree reaches 60-65%, the size of a foam hole is controlled to be below 20 mu m, the extruded optical fiber (1) coated with the buffer layer (2) is cooled by cooling water, the temperature of the cooling water is lower than 80 ℃, and the thin-wall thickness of the buffer layer (2) is controlled to be 0.2-0.3 mm;
in the step (c), 16 strands of fiber yarns are woven outside the buffer layer (2) to form a reinforcing layer (3), and the fiber pay-off tension is 0.5N-1N;
in the step (d), the outer protective layer (4) is formed by weaving the fiber yarns outside the reinforcing layer (3), the elastic modulus of the fiber yarns for weaving the outer protective layer (4) is more than 2.1Gpa, the outer protective layer works in the temperature range of-150 ℃ to 300 ℃, the outer protective layer (4) is formed by weaving 24 strands of fiber yarns, the weaving pitch is controlled within 10mm, the weaving density is more than 99.9 percent, and the fiber pay-off tension is 1N to 1.5N; or the outer sheath (4) is formed by externally wrapping the reinforced layer (3) with a film, the outer sheath works at the temperature of-150-300 ℃, the tensile modulus is greater than 200MPa, the thickness of the film is 50um, the wrapping tension of the film is 1N-1.5N in the wrapping process, and the wrapping angle of the film is greater than 60 degrees.
2. The manufacturing method of the optical cable for aerospace according to claim 1, wherein: in the step (b), the buffer layer (2) is a low-expansion stable buffer layer, and the buffer layer (2) is any one of expanded fluoride, foaming fluoride, copolyester or aromatic polymer.
3. The manufacturing method of the optical cable for aerospace according to claim 2, wherein: in the step (c), the reinforcing layer (3) is any one of polyimide fibers, modified aramid fibers, special glass fibers, metal-plated fibers, basalt fibers, carbon fibers and stainless steel wires, and is formed by weaving.
4. The manufacturing method of the optical cable for aerospace according to claim 3, wherein: in the step (d), the fiber of the outer sheath (4) is any one of polyimide fiber, modified aramid fiber, special glass fiber, metal-plated fiber, basalt fiber and carbon fiber, and the outer sheath (4) is formed by adopting a physical weaving mode.
5. The manufacturing method of the optical cable for aerospace according to claim 3, wherein: in the step (d), the film of the outer sheath (4) is any one of a polyimide film, an aromatic polymer film and a polyether ether ketone film, and the outer sheath (4) is formed in a wrapping mode.
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Cited By (3)
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CN114280744A (en) * | 2021-12-27 | 2022-04-05 | 远东电缆有限公司 | Optical fiber composite cable and preparation method and application thereof |
CN114397737A (en) * | 2022-01-28 | 2022-04-26 | 安徽光纤光缆传输技术研究所(中国电子科技集团公司第八研究所) | Aerospace optical cable assembly bending-resistant reinforcing method, optical cable assembly and verification method |
CN115045128A (en) * | 2022-01-08 | 2022-09-13 | 佛山市杰品玩具实业有限公司 | Spiral-structure rope belt fabric containing wound optical fiber filaments and production method thereof |
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